Renewable and Sustainable Energy Reviews 35 (2014) 336–346

Contents lists available at ScienceDirect

Renewable and Sustainable Energy Reviews

journal homepage: www.elsevier.com/locate/rser

Review of energy efficient direct pump controlled cylinder

electro-hydraulic technology
Zhongyi Quan, Long Quan n, Jinman Zhang
Key Lab of Advanced Transducers and Intelligent Control System, Ministry of Education and Shanxi Province, Taiyuan University of Technology, Taiyuan
030024, Shanxi, China

art ic l e i nf o a b s t r a c t

Article history: Hydraulic cylinder is an indispensable linear actuator in high power applications like construction
Received 4 December 2013 machinery. In order to reduce the energy consumption, the noise and the waste oil disposal pollution of
Received in revised form the hydraulic cylinder control system, the most direct method is adopting the direct pump control
2 April 2014
technology which eliminates the throttle losses in the main power line. In such system, by changing the
Accepted 8 April 2014
speed or the displacement of the pump, the pressure and volume flow will be matched with the need of
loads. To date, research works in this field have been reported in many articles, but they are scattered
Keywords: and written in different languages. An overview which can summarize the latest development of this
Energy efficiency of hydraulic system technology appears to be necessary. This paper provides a comprehensive review on this technology,
Direct pump controlled cylinder
aiming at clarifying recent advances and outlining potential challenges in the research and application of
Electro-hydraulic control technique
this technology. The review mainly covers three parts: system structure, control, and derived energy
Energy recovery system
recovery system. Also the evolvement of the electro-hydraulic cylinder control system is introduced. The
review indicates that attentions should be paid to the control and energy recovery plan of the direct
pump controlled cylinder system, and to the newly proposed asymmetric pump controlled differential
cylinder technology. It is envisaged that the information gathered in this paper will be a valuable one-
stop source of information for researchers, as well as providing a direction for future research in
this area.
& 2014 Elsevier Ltd. All rights reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
2. Evolvement of hydraulic cylinder control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3. Pump controlled double rods cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
4. Pump controlled differential cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
4.1. Conventional pump controlled differential cylinder system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.2. Asymmetric pump controlled differential cylinder system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
5. Control of pump controlled cylinder systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
6. Energy recovery system based on pump controlled cylinder system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
7. Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
7.1. Further verification of asymmetric pump controlled system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
7.2. Robust control method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
7.3. New energy recovery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
8. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Acknowledgement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

n
Corresponding author. Tel.: þ 863516014551.
E-mail address: [email protected] (L. Quan).

http://dx.doi.org/10.1016/j.rser.2014.04.036
1364-0321/& 2014 Elsevier Ltd. All rights reserved.
 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346 337

1. Introduction hydraulic cylinder control system in terms of modifying the

system structure and implementing advanced control approaches.
Electro-hydraulic system as one of the fundamental compo- In this paper, state of the art of the pump controlled cylinder
nents has been applied in many equipments, such as the con- technology will be reviewed. First the evolvement of cylinder
struction machines, the agricultural machines, and the aeroplanes. control system is presented to introduce the advantage of the
Common to these applications is that high power is often required pump control technology. Then the direct pump controlled double
to perform the desired work, for example moving material or rods cylinder technology and direct pump controlled differential
lifting heavy weights. The power for such drives is often generated cylinder technology are overviewed respectively in Sections 3 and 4.
by a centralized source, usually an internal combustion engine or a Existing control strategies for pump controlled cylinder system will
high power electric machine. Using fluid power systems the power be reviewed in Section 5. And the energy recovery technology based
is easily distributed via hydraulic lines to either linear or rotary on the pump controlled cylinder is also discussed in Section 6. In the
drives. It is estimated that by the year of 2000, the world market of end the major challenges that this technology faces will be summar-
electro-hydraulics is about 30–35 billion dollars per year, and is in ized. The aim of this review is to provide a comprehensive perspec-
steady growth. Meanwhile, energy saving concerns for hydraulic tive on the challenges and tendency of this technology for the
system has been raised with the numerical application of heavy researchers and help them seeking breakthroughs for hydraulic
equipments. Electro-hydraulic system mounted equipments often system.
work around the clock and output high power in handling heavy
loads. The energy consumption and the waste gas emission of such
systems therefore stay high. Take one of the most popular 2. Evolvement of hydraulic cylinder control system
construction machines, 20-t load sensing controlled hydraulic
excavator as an example. Such type excavator usually requires a Based on the circuit types, hydraulic cylinder control system
diesel engine of more than 110 kW, which consumes at least can be classified as valve controlled system and pump controlled
33litre fuel in an hour. The amount of NOX and CO emitted by system. Valve controlled hydraulic systems have been widely
this machine is considerable. But only 30% of the consumed energy applied in conventional equipments and machines implement
is used in moving loads. While more than 60% of the energy is due to its low cost and simple structure. However it faces an
consumed in power losses and driving of hydraulic systems [1]. obvious drawback, the enormous energy loss, i.e. throttling loss at
Therefore even a small improvement in the hydraulic system the control valves [6,7]. Study on the energy analysis of fluid
efficiency will have a significant impact on the total energy power system has shown that 35% of the input energy of a valve
efficiency of the machine. controlled system is consumed in controlling valves. Such poor
Previously, several literature reviews have been presented energy efficiency will lead to the high engine installed power and
regarding the application of electro-hydraulic technology in will generate great amounts of heat during the operation of the
various fields for energy saving purpose. Zhang et al. overviewed equipment. And overheat is also a significant reason that causes
the application of hydraulic cylinder based wave energy genera- breakdown of the machines. To decrease the temperature of the
tion in China [2]. [3,4] reviewed the high pressure hydrostatic system, additional cooling system is required but it will also
technology in energy efficient food production and processing. further increase the cost and the installed power of the equip-
And the status of hybrid construction machinery, one of the most ments. And as an open circuit, valve controlled system usually
important application fields of the electro-hydraulic technology, needs large amount of hydraulic oil for the operation of the circuit,
was overviewed in Ref. [5]. Above papers have presented the which to some extent increases the cost of the system and raises
importance of electro-hydraulic technology in energy saving or pollution problem when disposing the oil. Although the develop-
generation applications, but the latest development of electro- ment of load sensing technique effectively reduces the throttling
hydraulic circuit and control technology has not been reviewed. loss of the control valve, eliminating of such loss in valve
Based on the type of the actuator, such technology can be controlled system is impossible.
classified as two types: rotary motion control, i.e. hydraulic Another type of hydraulic system is pump controlled system.
pump/motor, and linear motion control, i.e. hydraulic cylinder. Such system falls into two types, open circuit as shown in Fig. 1
Hydraulic rotary motion control is usually implemented in appli- (a) and (b) and closed circuit which is also called direct pump
cations like the slewing system and the walking system of controlled system, as shown in Fig. 1(c) and (d). In open circuit
construction machines and some low power applications. The pump controlled systems, control valves still place important roles
control of the hydraulic pump/motor is simple due to the sym- in controlling the flow direction of the oil in the chambers of the
metric distribution of the pressure in the system. The hydraulic cylinder, so the energy efficiency of the system is directly affected
cylinder has attracted more attention and has gained widely by the efficiency of the valves. Some schemes still need throttling
applications. Compared with electromechanical linear actuator valves in the main power lines. And due to the throttling losses in
and pneumatic cylinder, the high output force of the hydraulic the control valves and pressure losses, the energy efficiency of the
cylinder system makes it indispensable in high power linear open circuit system is degraded.
motion applications like press machine, bending machine, con- In order to eliminate the throttling loss and reduce the overall
struction machine, short distance lifting equipment, etc., making energy consumption of hydraulic system, direct pump controlled
the hydraulic cylinder the most emblematic actuator in electro- system was proposed. As can be seen from Fig. 1(c) and (d), pump
hydraulic systems. But hydraulic cylinder control system also controlled cylinder system, different from valve controlled system,
faces limitations. The energy efficiency of hydraulic control is a closed-control structure, in which both chambers of the
system is lower than that of the electromechanical system and cylinder are connected with the pump. The primary power sources
pneumatic system. And the controllability is also poor due to the of these systems are usually electric machines. Compared with the
significant nonlinearity and asymmetric of the system, especially valve controlled system and open circuit pump controlled system,
in the differential cylinder control system. The poor energy the closed pump controlled system, which does not need control
efficiency and control performance of the cylinder control system valves, suffers no throttling loss in the main power lines and needs
significantly undermined the performance of the overall equip- less hydraulic fluid, i.e. oil, in the operation. And based on the
ments. So over the past decades, efforts have been focused on pump controlled system, energy recovery solutions for kinetic
improving the energy efficiency and control performance of the energy and potential energy are possible. Hence the installed
338 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346

Fig. 1. Basic schemes of open circuits (a and b) and closed circuits (c and d).

engine power, overall equipment energy consumption, the gener-

ated heat will be greatly reduced. Investigation on the energy
efficiency comparison of the two kinds of hydraulic systems
showed that the energy efficiency can be improved more than
40% by using advanced pump controlled systems. One more
advantage of utilizing pump controlled system is that the power
can be delivered by wire instead of by steel pipes. Hence the pump
controlled system is obviously a better solution to realize the
green in fluid power system, i.e. low noise, high efficiency, less
Fig. 2. Pump control cylinder circuit with one chamber preloaded.
pollution, making it the developing trend of electro-hydraulic
control technology.
Although the energy efficiency can be improved enormously 3. Pump controlled double rods cylinder
with direct pump controlled technology, limited by the dynamic
performance of the pump, such principle could just be used in the In 1973 and 1979, Hahmann and Spockhoff introduced the
pump controlled motor system with large power in the early time. circuit principle of pump controlled motor into the control of
It is not until 1980s that control of the cylinder closed loop with hydraulic cylinder in their dissertations, and researched the static
pump became possible. By using pump displacement and valve and dynamic performance of the pump controlled cylinder system
stroke double closed loop controller, the dynamic response per- [10,11]. The circuit is shown in Fig. 2.
formance of axle and radial piston pump reach almost the same This hydraulic system uses an oil exchanging valve with
level as normal proportional valves. With higher supply pressure constant back pressure to exchange heat; only one chamber of
their frequency response in small signal range reaches more than the hydraulic cylinder is preloaded. Therefore the natural fre-
50 Hz [8,9], which is sufficient for today's most industrial and quency of the system is low, which negatively affects the dynamic
mobile applications. Based on the type of the cylinder, the performance of the system.
technology falls into two kinds, the pump controlled double rods In 1988, Berbuer proposed a new cylinder preload principle which
cylinder, as shown in Fig. 1(c) and the Pump Controlled Differential consists of a constant pressure source and orifices, as shown in Fig. 3.
Cylinder, as shown in Fig. 1(d). The development of the system With this new principle, both chambers of the cylinder are
circuit of both the two systems will be presented in the following preloaded with hydraulic pressure, the natural frequency and load
sections. rigidity of the pump controlled cylinder system are increased,
 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346 339

pressure oil tank or a low pressure accumulator, and the leakage oil
of the hydraulic pump is also led to the oil tank. The speed and the
moving direction of the cylinder are controlled by the servo motor
driven constant pump. In 1990, German Company Demag applied
for a patent that applies this principle into the control of plastic
injection modeling machine [14]. In 1992, German Company Lieb-
herr proposed a close-loop controller for double rods cylinder based
on the electronic controlled proportional pump and applied this
technology in the airplane control system [15]. The circuit is the
same as that shown in Fig. 5. But the constant displacement pump is
Fig. 3. Pump controlled double rods cylinder circuit with two chambers preloaded. replaced by a proportional pump, and a small pump is added to
exchange the heat when cylinder is positioned. Kazmeier researched
the double rods cylinder system for the airplane application. In his
25 research, both constant pump controlled system and proportional
pA pB pump controlled system were analyzed. And a fuzzy logic based
20 control method was proposed to improve the static and dynamic
Pressure p / MPa

performance of the system. The system was implemented on an

15 A340 airbus and conventional steel pipes were replaced by the
novel Power-by-Wire actuator system, which reduced the weight of
the plane at about 700 kg. Safety and reliability of the plane was also
10
improved [16]. Habibi and Goldenberg proposed the principle of
direct pump controlled symmetric linear actuators [17]. Though the
5 actuator was not a typical double rods cylinder, this system is
applicable for double rods cylinders. The pump controlled double
rods cylinder has also been applied in the flight control [18–21].
0
-10 -5 0 5 10 Kang et al. proposed a hydraulic power regulator for flight control
system on the basis of a modified the direct pump controlled double
Pump displacement a/ %
rods cylinder system [22]. A hydraulic lock was introduced to
improve the stiffness and energy efficiency of the system. But on
25 the other hand the existence of proportional valve in the power line
degrades the energy efficiency to some extent.
Double rods cylinder as a symmetric actuator is simple to
20 pA pB control. But its application is limited by the small output force and
Pressure p / MPa

the install space. At present the double rods cylinder control

15 circuit design is no longer a research focus.

10
4. Pump controlled differential cylinder

5 Because of the requirements on the installation space and

output force, at least 80% of the electro-hydraulic control system
0 adopts the differential cylinder as actuator. Different from double
-20 -10 0 10 20
Pump displacement a/ %
Fig. 4. Pressure gain curves of pump controlled double rods cylinder.

making the system possess a similar characteristic as the valve

control system [12]. But in this circuit one pump and one motor
are required to exchange heat. Fig. 4 shows the pressure gain
curves of the above two systems.
It is clear that only one chamber's pressure changes with the Fig. 5. Speed variable pump controlled double rods cylinder circuit.
swing angle of the pump when adopting the traditional constant
pressure control. But by adopting the two-chamber preload
principle, the pressures in both chambers vary with the swing
angle of the pump in the opposite direction at the same time. The
pressures of both chambers are equal when no load is acted. And
this balance pressure can be controlled by adjusting the value of
the orifices. When the cylinder is accelerating or there is load force
acted, pressures of both chambers change at the same time.
In 1990, German Company Parker Hannifin applied for the
patent of a new pump controlled double rods cylinder system for
the manipulator system of airplanes [13]. Servo motor is adopted
to drive a constant pump. The system scheme is shown in Fig. 5.
The characteristic of this system is that two chambers of the Fig. 6. Pump controlled differential cylinder circuit compensated with hydraulic
cylinder are preloaded through two check valves by a constant low- transformer.
340 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346

rods cylinder, the sectional areas of the two chambers are not cylinder system, as well as its applications and energy efficiency
equal. Therefore the oil flows of the two chambers are different, improvements. In this section, two types of systems will be
resulting in an asymmetric volume flow in the two ports of the introduced, system controlled by conventional pumps and system
cylinder. And unlike valve controllled system or open circuit, the controlled by asymmetric pumps.
asymmetric flow circulates in a closed loop in the direct pump
controlled differential cylinder system. If cannot be compensated, 4.1. Conventional pump controlled differential cylinder system
this asymmetric flow will cause several problems like the inaccu-
racy of piston positioning and the poor control performance. The In 1994, Lodewyks. R, in IFAS RWTH Germany, put forward the
energy efficiency is also undermined if the asymmetric flow is not circuit principles that use a hydraulic transformer or two coaxial-
well compensated. Hence researches have been focused on the driven proportional pumps to compensate the asymmetrical flow
compensation method of the asymmetric flow in the differential in differential cylinder. Figs. 6 and 7 are the circuits [23]. Feuser
from Rexroth, adopting the constant chamber pressure preload
principle, researched the static and dynamic performance of the
circuit in Fig. 7. This technology has been successfully used in the
control of presser [24].
In 1998, Ivantysynova applied the direct pump control technol-
ogy in construction machines. And their research revealed that
compared with the valve controlled system, adopting the pump
control technology can not only simplify the circuit, reduce the
weight, improve the capability and energy efficiency, but also can
make the control process easier. The research work showed a good
Fig. 7. Differential cylinder circuit controlled by two proportional pumps. future for the pump control technology [25]. Then Kahmfeld put
forward the pump controlled differential cylinder circuit principle
that adopts one hydraulic pump cooperated with two hydraulic
controlled check valves to compensate asymmetrical flow. The
system scheme is shown in Fig. 8 [26]. Meanwhile, the possibilities
of applying this technology in concrete pump truck, wheel loader
and multi-joint manipulator were researched [27,28].
In other studies, Japanese companies Yuken and Nachi devel-
oped the circuit principle shown in Fig. 8 into an integrated unit
and put them into practice use. The product has been used in
6-DOF motion simulator, presser, and other fields. A similar system
Fig. 8. Pump controlled differential cylinder with check valve balancing the was proposed by the American company Vickers. They applied for
flow [26]. the patent of the closed loop control of the differential cylinder

Fig. 9. Different asymmetric flow compensation circuits. (a) Closed circuit using two separate motor drive pump units (b) hydraulic transformer (c) closed circuit using
connected two pumps (d) open circuit using two separate motor drive pump units (e) compensating by check valves and (f) retrieving oil by accumulator.
 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346 341

which uses a AC servo motor to drive the constant displacement 4.2. Asymmetric pump controlled differential cylinder system
pump and uses the hydraulic controlled check valves to balance
the flow. This technology was later used in the plastic injection Though pump controlled differential cylinder system has been
modeling machine [29]. Jiang et al. researched the system of ship proved energy efficient in many fields, existed methods still face
steering controlled by the speed-variable pump [30]. Wang et al. limitations. The asymmetrical volume flow cannot be easily compen-
proposed a system that balances the unequal flow through one of sated by single pump. High displacement check valves are needed as
the pilot-operated check valves to the low pressure side whose shown in Fig. 9(e), but the asymmetrical flow will increase energy
pressure is close to the charge pump [31]. In another research, the exchange in the check valve, hence increasing the energy consump-
asymmetric volume flow is compensated with a double-pump tion of the system. To further reduce the energy consumption,
system [32]. auxiliary components are necessary. But unfortunately the auxiliary
Recent researches have demonstrated that the closed pump- components will increase the cost and complexity of the overall
controlled systems directly driven by servo motor, i.e. PMSM [45] system. In order to compensate the asymmetric flow, solutions
or SRM [33], features many merits, such as wide speed range, high shown in Fig. 9 have to sacrifice some of the advantages of the
accuracy, high energy efficiency, high power density, etc. [34]. direct pump controlled circuit. To overcome this drawback, novel
Helduser first proposed the concept of hydraulic pump-controlled pump structure and system integration scheme are demanding.
system, driven by gear pumps and variable speed AC servo motors Quan and his group studied the structure of the vane pump and
for injection molding machines [35]. Quan and Neubert researched piston pump. In their research, three novel pumps were designed
the servo motor and constant pump closed loop controlled and constructed [41,42]. The structures of these pumps are shown
differential cylinder system. During the research, several circuit in Fig. 10. According to the fact that there are 4 ports in the double
principles were suggested to compensate the asymmetrical flow of acting vane pump, the asymmetrical flow compensation system
the differential cylinder. Especially the circuit that control the principle in Fig. 10(a) was proposed. By connecting the original
differential cylinder closed loop with two separate speed variable pressure port to the piston chamber, the original suction port will
pumps, not only compensates the asymmetrical areas of the be divided into two independent ports. One is connected with the
differential cylinder, making the dynamic performance in the ring chamber of cylinder and the other with the oil tank, basically
two directions of the system the same, but also increases the compensating the area ratio of the differential cylinder with port,
driving power of the system. The newly developed sum-pressure then through regulating the stroke of vane, the flow can be
principle preloads both chambers of the cylinder as two hydraulic balanced. Based on this principle, piston pump can be modified,
springs that makes the system have same characteristic as valve as shown in Figs. 10(b) and (c). One of the two original suction
controlled circuit. Experiments proved that the system has large ports is divided into two ports. Port PA is connected with piston
output power and a similar static and dynamic performance as chamber; PB is connected with ring chamber. By regulating the
that of the proportional valve controlled system, but has higher length rate between port 1 and 2, or the piston numbers pass
energy utilization efficiency than the valve controlled system, through the distributing flow port 1 and 2, the flow will be
making the circuit more suitable for the equipments that need balanced basically. Due to the asymmetric structure of the new
large power [36]. Johansson and Petter studied the application of pumps, they are named as asymmetric pump, or three-port pump.
the pump controlled differential cylinder technology in the battle Fig. 11 shows the plate of the new differential pump.
plane [37]. Cetinkunt et al. applied the pump controlled cylinder With this new pump, the cylinder control system no longer
system in the bucket control of loaders, but asymmetric flow needs auxiliary valve to compensate the asymmetric flow of the
compensation was not considered [38]. Fig. 9 summarizes the differential cylinder. Moreover, the kinetic energy and the poten-
existing compensation circuits for pump controlled differential tial energy generated in the motion of the cylinder can also be
cylinder system. Based on these circuits, some improvements or directly recovered [43,44]. Furthermore, a PMSM driven asym-
assisting circuits can be developed. Ho and Ahn proposed an metric pump controlled cylinder system was investigated in [45].
assisted hydraulic circuit with three directional controlled valves The proposed system is shown in Fig. 12. The system can operate
for conventional hydraulic transformer [39]. in four quadrants, as shown in Fig. 13. According to the direction of
In a comparative study, Zhang et al. investigated the energy the force on the piston and the direction of the piston speed,
efficiencies of different direct pump controlled cylinder systems in charging and discharging of the accumulator is controlled. There-
the injection molding machine application [40]. The energy fore the energy can be directly recovered with only one pump.
efficiency of five different systems were studied and compared. To demonstrate the energy efficiency of the asymmetric pump
They are induction motor driven constant pump, variable speed controlled system, efficiency comparison was carried out. What
induction motor driven constant pump, induction motor driven Fig. 14 shows are the comparison results of the energy consump-
variable displacement pump, variable speed induction motor tion in one working cycle that the pump controlled double rods
driven variable displacement pump, and AC servo motor driven cylinder, the double pump controlled differential cylinder and the
constant pump. Experiments were carried out on an injection asymmetric pump controlled differential cylinder separately con-
molding machine. The research results confirmed that: in the trolling the same plastic injection modeling machine lamping unit.
partial load and no-load conditions, induction motor driven It is clear that the single asymmetric pump controlled system
constant pump system suffers from the large overflow, throttle consumes less energy than the double-pump solution and reaches
losses, and low efficiency. In the induction motor driven variable
displacement pump system, the overflow losses are completely
eliminated, however the big motor idling loss still exits. On this pT pA pT pT
basis variable speed control is introduced to match the motor
output power and the hydraulic load. And the energy efficiency is 1
pA 1
improved by 26.5%. The research also showed that the energy pA
efficiency of the AC servo motor driven constant pump system is pB pB
the highest, which can save 88% of the energy compared with
induction motor driven constant pump. Also the structure and pB
2 2
good dynamic performance can be optimized by applying the AC
servo motor driven constant pump circuit. Fig. 10. Basic principle of asymmetric pump.
342 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346

12

Energy consumption P/kWs

10
Sim energy motoor
8

4
Sim energy pump
2

0
0 0.3 0.6 0.9 1.2 1.5
Time t/s

20

Energy consumption P/ (kW·s)

Fig. 11. Plate of the asymmetric pump [43]. 16

Test energy motor

12
Sim energy motor
8

4 Sim energy pump

0
0 0.3 0.6 0.9 1.2 1.5
Time t / s

Fig. 12. Circuit of the PMSM driven asymmetric pump controlled cylinder system
[45].
12

10 Sim energy motor

Energy consumption P/kWs

v v
F 8
F
m m
FL FL 6
pA pB pA pB
M M
3~ 3~
4
pT pT Sim energy pump
Generator Motor
II I 2
v III IV v
F F 0
0 0.3 0.6 0.9 1.2 1.5
m m
FL Time t/s
FL
pA pB pA pB Fig. 14. Energy consumption comparison between differential cylinders controlled
M M by different pumps [46]. (a) Double rods cylinder control system (b) double pump
3~ 3~
controlled differential cylinder (c) asymmetric pump controlled differential
pT pT
Motor Generator cylinder.

Fig. 13. Four-quadrant operation of the asymmetric pump controlled circuit.

the same energy efficiency performance as the double rods controlled cylinder system. Although the structure of the electro-
cylinder control system [46]. hydraulic servo systems is simple, these systems are nonlinear,
high order, and relatively difficult to control. Moreover varying
working condition and parameters further increase the control
5. Control of pump controlled cylinder systems difficulty. In past decades, many investigations were put forward
on the control of electro-hydraulic systems. Majority of them were
In addition to system exploration, efforts have been put into the proposed for valve controlled system or open pump controlled
control methods to improve the performance of the pump system, but they share the some fundamental electro-hydraulic
 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346 343

principles with closed pump controlled system, especially in the 6. Energy recovery system based on pump controlled cylinder
nonlinear control of hydraulic servo systems. system
System uncertainties and variable load are two of the electro-
hydraulic servo systems' common features. To deal with this pro- One of the most significant merits of the pump controlled
blem, many approaches were proposed, such as PID based methods, system is that the energy recovery becomes applicable. According
nonlinear control [47], adaptive control approaches [48–50], to the type of the recovered energy, energy recovery technology
sliding mode control approaches [51–53], fuzzy control [54–57], can be classified into two kinds, recovery system for kinetic energy
robust control [58], quantitative feedback control [59], and hybrid and recovery system for potential energy. Kinetic energy generally
control methods [60,61]. These methods are also applicable for direct occurs in the regenerative braking operation of travelling system
pump controlled systems and some of them already have been or slewing system. Potential energy occurs in the descending
applied. operation of lifting systems where pump controlled cylinder
Specifically for direct pump controlled cylinder system, there system has been widely applied, such as the boom and stick and
are also some studies reported. Cho and Burton proposed a arm of the excavator, the bucket of the loader, and short-distant
feedback-feedforward based simple adaptive control method for crane and forklift. In conventional valve controlled cylinder
direct pump controlled symmetric actuators like double rods systems, the potential energy generated in descending operation
cylinders [62]. Wang et al. studied the nonlinear characteristic of of these systems is mostly converted into heat in the main throttle
hydraulic pump controlled system and applied singular perturba- valve, wasting large amount of energy. Based on the pump
tion theory to simplify hydraulic control design [63]. Based on controlled cylinder structure, such energy can be recovered and
their analysis, a robust control law was proposed. A pump reused in either hydraulic storage manner or electric storage
controlled asymmetric cylinder system was used to testify the manner. Many energy recovery systems have been proposed on
control laws. Perron et al. proposed a sliding mode controller for a the basis of open pump controlled cylinder circuit [78–80]. But few
Brushless DC motor driven pump-cylinder system [64]. The time were proposed using closed circuit. A feasible circuit was proposed
efficiency of the system was improved. Deng et al. studied the by Liebherr Company [81], as shown in Fig. 15. A high power
cylinder system in rapid-erection system and proposed an intel- differential cylinder composed excavator system which is con-
ligent control method based on BP neural network for the prime trolled by two flow displacement variable pumps was studied. The
power source, i.e. diesel engine in this paper [65]. Experiment bucket and the stick cylinders are controlled in open loop, and the
results showed that the proposed method can effectively stabilize boom cylinder is controlled in closed loop. The potential energy
and expedite the erection process and at the same time reduce the generated in boom descending are stored by the accumulator
fuel consumption. Lee et al. adopted an adaptive fuzzy controller connected in the oil compensate port, realizing the integration of
with self-tuning fuzzy sliding-mode compensation for electro- the boom drive and control. Field experiment results showed that
hydraulic system. The method was testified on a direct pump the manufactured prototype reduced the engine installed power
controlled double-rod cylinder system. And results showed that by 25% and meanwhile increased the boom lifting speed and the
the proposed method has a good performance in the position slewing acceleration by 80%.
control of the cylinder [66]. Ahn and Dinh studied the principle of
direct pump controlled differential cylinder system and proposed
several control methods. An electro-hydraulic test machine was
proposed and along with quantitative feedback theory and robust
self-tuning quantitative feed controller in Refs. [67,68]. The pro-
posed test machine consists of two AC servo motor driven closed
pump controlled differential cylinder systems, in which one
cylinder is the force generator, the other cylinder is the distur-
bance generator. Both cylinders are connected with a spring load
system. With the proposed structure, the test machine can be
adaptive to various control purposes. Then a self-tuning adaptive
control algorithm based on quantitative feedback theory and
gradient descend method and back propagation algorithm was
employed for the force control of the test machine. The effective-
ness of the constructed test machine and the proposed control
method were demonstrated through simulation and experiment
verifications. In their further research, general fuzzy PID control
method, extended Kalman filter based online smart tuning fuzzy
PID control algorithm, self-tuning grey predictor based fuzzy PID
control algorithm, and back stepping control method were pro-
posed for the force of the test machine [69–73]. In another
research, a DC motor driven closed circuit was studied and
controlled with quantitative feedback control approach [74].
Chiang applied the direct pump control cylinders into the pitch
control of wind turbine [75]. An adaptive fuzzy controller with
self-tuning fuzzy sliding-mode compensation was proposed for
the system. Zhang et al. employed model following control and
resonance ratio control to improve the anti-disturbance perfor-
mance of system [76]. To addressing the saturation, dead zone
nonlinearity, and time variability of the SRM driving pump
controlled differential cylinder system, closed loop Iterative Learn-
ing Control (ILC) method was also employed to perform robust
position control [77]. Fig. 15. Accumulator based energy recovery system for hydraulic excavator boom [81].
344 Z. Quan et al. / Renewable and Sustainable Energy Reviews 35 (2014) 336–346

7. Challenges 8. Conclusion

7.1. Further verification of asymmetric pump controlled system With the rising concerns for the energy efficiency of fluid
power transmission system, energy saving technology for such
Although the development of asymmetric pump has been system is demanding, which lead to the emerging of pump
proved effective in compensating the asymmetric volume of the controlled system. Pump controlled cylinder system as the most
differential cylinder control system, the generalization of such popular pump controlled system, has been applied in many heavy
pump is facing several challenges. The manufacturing complexity working conditions, the energy efficiency of which matters a lot to
of the asymmetric pump is higher than conventional pumps. The the efficiency of the overall equipment. This work gathers and
application of this new pump have not been fully explored, the summarizes the development and the latest status of the pump
performance of asymmetric pump controlled cylinder system in controlled cylinder technology, which are scattered in various
high power or heavy load fields, such as construction machines, literatures. Different types of hydraulic circuits are summarized
has not been verified. To be applicable in high power or heavy load for the convenience of researchers. Although this technology is
fields, new system scheme is necessary. Furthermore, the dynamic still facing limitations and challenges, new solutions are coming
control of this new system lacks investigation. up. With the improvement of energy efficiency and dynamic
performance, it is identical that the direct pump controlled
cylinder system as a novel electro-hydraulic actuator system will
7.2. Robust control method have more and more applications. And in the end, it is hoped that
this paper will be a valuable source of information for researchers,
Although closed pump controlled system has been recognized machine designers and manufactures.
as a system with many advantages over pump controlled system
and open circuit pump controlled system, its control has not been
fully researched yet. Some popular methods like hybrid control Acknowledgement
have not been applied. And with many control approaches
proposed for electro-hydraulic system, comparative studies should The authors would like to thank the anonymous reviewers for
be carried out for various applications. Besides, control of load their valuable comments. This work is supported by the National
variation and disturbance of such system are still need exploration. Natural Science Foundation of China (Grant no. 51375324).
Moreover, the resonance between electric drive system and the
hydraulic system is a serious problem for the overall stabilization
of the system. Conventional notching filter and disturbance References
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